The University of Michigan, Ann Arbor Engineering Research Center for Reconfigurable Manufacturing Systems TA-3 Projects In-Process Metrology

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.2 Motivation of TA-3 Build a world-class center of expertise for the research and development of rapid non-contact inspection methods. Conduct R&D motivated by industry inspection needs. Create educational tools in inspection and metrology. Bridge between end-users and equipment/solutions suppliers. (Evaluate specs and performance)

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.3 Results of TA-3: In Process Metrology Our results in Metrology are divided into two areas: 1.Metrology infrastructure i.e. methodologies and algorithms. Each of the listed items is backed up with a report or paper. 2. Metrology hardware i.e. Machines and devices developed for specific applications.

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.4 TA-3 Infrastructure: Computer Vision Algorithms for precise measurement of complex volumes using 3D vision Real time vision algorithms for dimensional measurements Algorithms for precise calculation of the diameter of pores Algorithms for quantification of small indents on autobody panels Hardware and algorithms for detecting pores inside small diameter bores

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.5 TA-3 Infrastructure: Free Form Surface Inspection Methodology: Methodology for fixtureless inspection of free form parts Algorithms: Algorithms to support the above methodology: –3D reconstruction algorithms –Automatic tracking algorithms

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.6 TA-3 Infrastructure: Measurements Design concepts and algorithms for the reconfigurable inspection machine Real time flatness and parallelism measurement techniques for prismatic machined parts Algorithms to convert non contact probe measurements to contact CMM measurements for comparison (“Virtual ball”) Laser technology and algorithms to identify residual boring marks in real time Self calibration algorithms Benchmarking study of all available non-contact, high-precision measurement technologies Laser technology and algorithms for error corrections and alignment of machine tools

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.7 Reconfigurable Inspection Machine-RIM Laser probes Slide system Engine cylinder head Vision system Same machine New Configuration

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.8 Plant floor testing (2/ ) RIM –Technology Transfer GEMA – Dundee, MI GM “RIM”- Flint Plant

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.9 Inspection of Complex Surfaces Stage Controller Probe Controller Accomplishments: Designed and built a laboratory prototype inspection machine for turbine blades. Developed algorithms for turbine blade inspection and performed automatic inspections. Generate interests from non-automotive industry (e.g. Aerospace Industry) Objective: To develop a rapid and accurate reconfigurable optical system for inspecting a part family with sculpture surfaces

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.10 Inspection of Complex Surfaces Linear Motion Stages Rotary Stage Inspected Part Computer Non-Contact Laser Probe Blade Inspection Machine (BIM)

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.11 TA3 Projects 1Cylinder Bore Inspection PrototypeBig 3 - Built – (DEMO) 2Detection of Surface Defects in Small Diameter CylindersBig 3 – requested (DEMO) 3In-line Valve Seat InspectionBig 3 – requested (DEMO) 4 Reconfigurable System for Turbine Blade FinishingNSF & W. Robotics 5Inspection of Auto-body Panels (Redirected to Research Project)For our Post Docs 6 Dimensional Measurement of BoresIOMS/STTR 7Benchmarking High-precision Non-contact SensorsY-12 Completed 8RIM Technology TransferGEMA -Stopped 9Automatic Detection of Porosity in Engine PistonsDCX - Stopped 10Measurement of Combustion Chamber VolumeCognitens -Stopped

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.12 Project #1 - Cylinder Bore Surface Inspection Prototype Goal Build a portable machine prototype for bore inspection technology (V and L blocks) that meets production line rates ( about 20 sec.) Deliverables The prototype was built and integrated The software for data collection and analysis is operating and will be improved Technology Transfer (to be discussed)

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.13 Full Scale Prototype Four laser probes V-8 Engine Inspection Setup

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.14 Future Work Technology transfer of prototype system Optimization of parallel detection at the ERC Study detection of rough hone or boring stages marks Evaluate the possibility of measuring dimensional properties of the bore

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.15 Project #2 - Inspection of Surface Defects in Small Diameter Bores Goal Surface defects detection (mainly porosity) in small diameter holes Deliverables Stage 1 (Completed) –Literature review –Problem analysis –Concepts suggestion Stage 2 (To be completed12/07) –Proof of concept Stage 3 (To be discussed) –Build a prototype

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.16 Sight Pipe System CCD Sight PipePart Top view of the system Detected Pores Bore Image

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.17 Next Steps Optimize the pore detection algorithms Improve the mounting structure of the sight pipe system Increase the optical magnification to get higher resolution Upgrade the CCD and DAQ device for higher speed Continue the Mini CCD study Decide about building a demonstrator

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.18 Goal Develop an accurate technique for in-line measurements of valve seat properties: Profile (in Progress) Geometry (Roundness & Run out – to be evaluated) Deliverables Literature review (done) Alternatives evaluation (done) Concept development (in progress) Build a demonstrator (ME 450) Build a prototype (To be discussed) Project #3 - In-line Valve Seat Inspection

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.19 Experimental Setup For Valve Seats Measurement Current Setup 2-axis Aerotech motion stage system Optimet Conoprobe: single point laser range sensor Setup Improvements Addition of 3 rd axis system for multiple cross sections Portable demonstrator (ME450: senior design class) Critical Dimensional and Geometric Features Seat Angle (with respect to valve guide) Seat Length Roundness of critical seat Run-out of critical seat (with respect to valve guide)

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.20 Project #4 -Reconfigurable System for Turbine Blade Finishing The Goal: To develop a closed-loop system for Turbine Blades Finishing that includes: defects detection, machining and inspection Grinding Robot Blade Inspection Machine (BIM)

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.21 Integration of Measurement and Machining Location Calculator (Relative to the part) Correction Action Robot Part Sensor Measuring Machine CAD Model + - Motion Comman d Robot Location Measuring Machine location Finished Parts Data Processing Closed loop integration of measurement and machining Inspection machine detects and measures defects on turbine blade Defect coordinates fed to the automatic robot for machining Robot machines the defects Inspection machine validates machining

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.22 MOTIVATION Automated detection of defects on auto body stamped panels OBJECTIVES Development of technologies and methods for reliable, automatic surface curvature measurement DELIVERABLES Sound analytical understanding and proof of concept Implement the method for measuring dents on sheet metal parts ACCOMPLISHMENTS Surface defects quantitative characterization Appropriate technology is currently identified for surface defect analysis and a prototype was designed and is built. Project #5 - Inspection of Auto-body Panels ( New Title: Measurement of Small Curvatures) X Z

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.23 Set Up and Master Plate for Calibration Sample Master Plate Experimental Set Up Research tools

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.24 Project #6 - Dimensional Measurement of Bores Goals: Evaluate probe technology for dimensional measurement of cylinder bores combined with NCU inspection capability Develop rapid imaging system to inspect defect of interest inside the bore. Time frame for the project: 2-years

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.25 Dimension Sensing Probe Scatter from surface is imaged onto detector by lens. Image position changes with distance from probe to surface. Detector is position sensitive. Slip Ring Bore Surface Mirror Lens Detector Laser

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.26 Rapid Imaging System Set Up Fiber illumination source Monitor Borescope Rotary table

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.27 Questions are Welcomed! The End

NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan, College of Engineering TA-3 Presentation pg.28 Automatic Porosity Detection on Engine Pistons Goal Automatic porosity detection on engine pistons Deliverables Building a prototype for image acquisition of cylindrical surfaces Developing an algorithm for the auto-alignment of masks and templates Algorithms for automated porosity detection